U.S. patent number 7,311,793 [Application Number 11/256,283] was granted by the patent office on 2007-12-25 for laminate from which decorative films can be applied to a substrate.
This patent grant is currently assigned to 3M Innovative Properties Company. Invention is credited to James F. Pitzen, Kristin L. Thunhorst.
United States Patent |
7,311,793 |
Thunhorst , et al. |
December 25, 2007 |
Laminate from which decorative films can be applied to a
substrate
Abstract
A laminate from which decorative films can be precisely applied
to a substrate. The laminate includes a polymeric cover sheet
having opposite outer and inner major surfaces. A layer of
structured pressure sensitive adhesive is adhered to the inner
major surface of the cover sheet. The structured pressure sensitive
adhesive has a plurality of spaced passageways extending to at
least one edge of the layer of structured pressure sensitive
adhesive. A decorative film is adhered to the structured pressure
sensitive adhesive. A second layer of pressure sensitive adhesive
is adhered to the major surfaces of the decorative film opposite
the layer of structured pressure sensitive adhesive. A release
liner extends substantially across the second layer of pressure
sensitive adhesive and a portion of the structured pressure
sensitive adhesive.
Inventors: |
Thunhorst; Kristin L.
(Stillwater, MN), Pitzen; James F. (Maplewood, MN) |
Assignee: |
3M Innovative Properties
Company (St. Paul, MN)
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Family
ID: |
32174583 |
Appl.
No.: |
11/256,283 |
Filed: |
October 20, 2005 |
Prior Publication Data
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Document
Identifier |
Publication Date |
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US 20060032580 A1 |
Feb 16, 2006 |
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Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
Issue Date |
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10279334 |
Oct 24, 2002 |
6984429 |
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10004727 |
Dec 5, 2001 |
6773537 |
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09759795 |
Jan 12, 2001 |
6571849 |
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Current U.S.
Class: |
156/249; 156/247;
156/248; 156/297 |
Current CPC
Class: |
B44C
1/1725 (20130101); B44C 1/1745 (20130101); B44C
1/1758 (20130101); B65H 35/0013 (20130101); B65H
37/002 (20130101); B29C 66/472 (20130101); B29K
2023/06 (20130101); B29K 2023/12 (20130101); B29K
2067/00 (20130101); B65H 2555/30 (20130101); Y10S
428/914 (20130101); Y10T 428/1405 (20150115); Y10T
428/1481 (20150115); Y10T 428/24868 (20150115); Y10T
428/1467 (20150115); Y10T 156/1089 (20150115); Y10T
428/24851 (20150115); Y10T 428/1471 (20150115); Y10T
428/2848 (20150115); Y10T 428/1476 (20150115); Y10T
428/2486 (20150115); Y10T 428/28 (20150115); Y10T
428/1448 (20150115) |
Current International
Class: |
B32B
37/00 (20060101) |
References Cited
[Referenced By]
U.S. Patent Documents
Foreign Patent Documents
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43 04 825 |
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Aug 1994 |
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EP |
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0 570 515 |
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Jun 1996 |
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EP |
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Sep 1996 |
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EP |
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0 911 263 |
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Apr 1999 |
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EP |
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07-101618 |
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Apr 1995 |
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JP |
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9-138647 |
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May 1997 |
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JP |
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11-334981 |
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Dec 1999 |
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JP |
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2000-313562 |
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Nov 2000 |
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JP |
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WO 92/13924 |
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WO |
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WO 93/12147 |
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Jun 1993 |
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WO |
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WO 02/13980 |
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Feb 2002 |
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WO |
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Other References
Handbook of Pressure Sensitive Adhesives, 2.sup.nd Edition;
Contents; Donatas Satas, Editor; Von Nostrand Reinhold, N.Y.,
(1989). cited by other .
Brochure, "Introducing 3M.TM. Accentrim.TM. Products", 1999. cited
by other .
Operating Instructions, 3M M45 Precision Cutter, Type 19900, 1999.
cited by other.
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Primary Examiner: Tucker; Philip
Assistant Examiner: McClelland; Kim
Attorney, Agent or Firm: Patchett; David B.
Parent Case Text
CROSS REFERENCE TO RELATED APPLICATIONS
This application is a divisional of U.S. application Ser. No.
10/279,334, filed Oct. 24, 2002, issued as U.S. Pat. No. 6,984,429,
which was a continuation-in-part of U.S. application Ser. No.
10/004,727, filed Dec. 5, 2001, issued as U.S. Pat. No. 6,773,537,
which was a continuation-in-part of U.S. application Ser. No.
09/759,795, filed Jan. 12, 2001, issued as U.S. Pat. No. 6,571,849.
Claims
What is claimed is:
1. A method for making a laminate adapted for use to decorate a
substrate, the method comprising the steps of: providing a layer of
pre-mask material comprising a cover layer and a layer of removable
pressure sensitive adhesive firmly adhered to one surface of the
cover layer; providing a supply of decorative film tape comprising
a length of decorative film having opposite parallel edges and
opposite first and second major surfaces, the decorative film tape
further including a layer of adhesive along the second major
surface of the decorative film; providing a sheet of release liner
having opposite first and second major surfaces, with the first
major surface of the release liner adapted to be releasably adhered
to by the removable adhesive on the cover layer and by the layer of
adhesive on the decorative film; using a computer operated tape
applicator to sequentially apply to the first major surface of the
release liner a plurality of parallel discrete first lengths of the
decorative film tape by adhering the adhesive on the first lengths
of the decorative film tape to the first major surface of the
release liner; cutting the applied parallel discrete first lengths
of the decorative film tape to form display lengths of the
decorative film tape from the discrete first lengths of the
decorative film tape with the display lengths of the decorative
film tape having end portions and to form scrap portions of the
discrete first lengths between the end portions of adjacent display
lengths of the decorative film tape, which end portions of adjacent
display lengths of the decorative film tape are at predetermined
positions for intersections along the discrete first lengths of the
decorative film tape; removing the scrap portions of the discrete
first lengths of the decorative film tape from the release liner;
using the computer operated applicator to sequentially apply to the
first major surface of the release liner a plurality of parallel
discrete second lengths of the decorative film tape extending
transverse to the display lengths formed from the parallel discrete
first lengths of the decorative film tape and extending over the
end portions of the display lengths formed from the parallel
discrete first lengths of the decorative film tape; cutting the
applied discrete second lengths of the decorative film tape to from
display lengths of the second lengths of the decorative film tape
along the discrete second lengths of the decorative film tape with
the display lengths of the decorative film tape having end portions
and to form scrap portions of the discrete lengths between the end
portions, the end portions of the display lengths formed from the
second lengths of decorative film tape being at the predetermined
positions for intersections along the discrete first lengths of the
decorative film tape with the end surfaces on the end portions of
the display lengths of the decorative film tape formed from the
first and second lengths of the decorative film tape at each of the
predetermined locations for intersections closely spaced from each
other; removing the scrap portions of the discrete second lengths
of the decorative film tape to provide a plurality of display
lengths of decorative film tape in a predetermined decorative
pattern; and adhering the layer of removable pressure sensitive
adhesive on the layer of pre-mask material to the first major
surfaces of the plurality of display lengths of decorative film
tape in the predetermined decorative pattern and to portions of the
release liner between the display lengths of decorative film tape
to form the laminate.
2. The method of claim 1 wherein the step of cutting the applied
discrete second lengths of the decorative film tape to form display
lengths of the second lengths of the decorative film tape along the
discrete second lengths of the decorative film tape forms the end
surfaces on the end portions of the display lengths of the
decorative film tape formed from the second lengths of the
decorative film tape at each of the predetermined locations for
intersections spaced in the range of 0.005 to 0.12 inch or 0.013 to
0.3 cm from the end surfaces on the end portions of the display
lengths of the decorative film tape formed from the first lengths
of the decorative film tape.
3. The method of claim 1 wherein the said plurality of parallel
discrete second lengths of the decorative film tape are applied
with the edges of the parallel discrete second lengths of the
decorative film tape disposed at a 90 degree angle with respect to
the edges of the display lengths formed from the parallel discrete
first lengths of the decorative film tape.
Description
FIELD OF THE INVENTION
The present invention relates to methods and assemblies for
applying adhesive coated decorative objects to substrates such as
sheets of glass.
BACKGROUND OF THE INVENTION
U.S. Pat. No. 5,665,446 describes a method for applying
pressure-sensitive adhesive coated graphics to a substrate (e.g., a
sheet of glass) using a layer of pre-mask material comprising a
polymeric cover sheet or layer and a layer of removable
pressure-sensitive adhesive firmly adhered to one surface of the
cover sheet with the layer of pre-mask material being vented.
Generally that method includes the steps of adhering surfaces of
the graphics opposite their layers of pressure-sensitive adhesive
to the layer of pressure-sensitive adhesive on the layer of
pre-mask material, using a wetting liquid to wet the graphics, the
layer of pre-mask material and the substrate; placing the graphics
adhered to the layer of pre-mask material at a desired location on
the substrate; pressing out air and water from between the
substrate and the graphics adhered to the layer of pre-mask
material; allowing the wetting liquid to dry through the vents; and
removing the layer of pre-mask material to leave the graphics
adhered to the substrate.
U.S. Pat. No. 5,840,407 describes pieces of optical film, each of
which pieces has a layer of pressure-sensitive adhesive along one
surface, and an opposite outer major surface (e.g., a grooved
and/or vapor coated surface) so that the pieces visually simulate
decorative glass such as glass with beveled edges, or with a groove
along its length, or with a leaded appearance, or with a textured
surface, or visually simulate glass related structures such as
metal came. Such pieces of optical film have been applied to
substrates (e.g., window panes) in predetermined patterns using
automated application equipment, however, heretofore it has been
very difficult for persons such as homeowners to apply such optical
film on windows or other glass substrates with the precision needed
so that it provides the desired visual simulation.
U.S. Pat. No. 6,805,932 describes a method for persons such as
homeowners to apply to a substrate (e.g., a sheet of glass in a
window or mirror) decorative designs made using separate pieces of
optical film of the type described in U.S. Pat. No. 5,840,407, each
of which pieces has a layer of adhesive along one surface, and an
opposite outer major structured surface (e.g., a surface that is
grooved and/or vapor coated) so that the pieces visually simulate
decorative structures such as glass with beveled edges, or with a
groove along its length, or with a leaded appearance, or with a
textured surface, or glass related structures such as metal came.
Generally, that method comprises the steps of (1) providing a kit
including a layer of pre-mask material that is at least translucent
comprising a cover sheet with a layer of removable adhesive (e.g.,
pressure-sensitive adhesive) firmly adhered to one surface; a
predetermined printed design; and pieces of optical film having
peripheral shapes that correspond to parts of the printed design,
each of which pieces of optical film have a layer of adhesive
(e.g., pressure-sensitive adhesive) along one surface, and an
opposite outer major surface (e.g., a grooved and/or vapor coated
surface) so that the pieces visually simulate decorative
structures; (2) placing the pieces of optical film over portions of
the design corresponding to their shapes with the outer major
surfaces of the pieces of film along a common plane; (3) adhering
the layer of adhesive on the layer of pre-mask material to the
outer major surfaces of the pieces of film; (4) placing the pieces
of optical film adhered to the layer of adhesive on the layer of
pre-mask material at a desired location on the substrate, (5)
pressing the layer of pre-mask material and thereby the pieces of
optical film adhered to the layer of pre-mask material against the
substrate, during which pressing step the layer of pre-mask
material protects the outer major surfaces of the pieces of film
from damage; and (6) removing the layer of pre-mask material to
leave the pieces of optical film adhered to the substrate in the
predetermined design. Preferably the layer of pre-mask material is
or has been made transmissive of moisture vapor (e.g., a layer of
pre-mask material that is vented as described in U.S. Pat. No.
5,665,446), a wetting liquid is used to wet the pieces of optical
film, the layer of pre-mask material and the substrate prior to the
step of placing the pieces of optical film adhered to the layer of
adhesive on the layer of pre-mask material at a desired location on
the substrate, which wetting liquid is allowed to dry between that
step and the step of removing the layer of pre-mask material.
BRIEF SUMMARY OF THE INVENTION
The present invention is directed to a laminate from which
decorative films can be precisely applied to a substrate. The
laminate includes a polymeric cover sheet having opposite outer and
inner major surfaces. A layer of structured pressure sensitive
adhesive is adhered to the inner major surface of the cover sheet.
The structured pressure sensitive adhesive has a plurality of
spaced passageways extending to at least one edge of the layer of
structured pressure sensitive adhesive. A decorative film is
adhered to the structured pressure sensitive adhesive. A second
layer of pressure sensitive adhesive is adhered to the major
surfaces of the decorative film opposite the layer of structured
pressure sensitive adhesive. A release liner extends substantially
across the first and second layers of pressure sensitive
adhesive.
The structured pressure sensitive adhesives are adapted to be made
wet during application of the decorative film to a substrate with a
liquid that lubricates the adhesives so that the decorative film
can be applied to a substrate at a precise position. A variety of
aqueous or solvent based lubricating liquids can be used. A large
portion of the lubricating liquid is expelled from between the
substrate and the decorative film by pressure and/or evaporation
through the passageways to leave the decorative film firmly adhered
to the substrate at the position.
The decorative film can be a film filled with light-diffusing
agents to give an etched or sand-blasted appearance to the
decorative film when they are adhered by the second layer of
pressure-sensitive adhesive to a glass panel. The film can also
have light diffusing features that provide a beveled or v-groove
appearance when adhered to glass. Preferably, the decorative film
is a structured film which provides the optical appearances of cut
glass, such as described in U.S. Pat. No. 5,840,407. The structured
pressure sensitive adhesive is preferably selected to form a bond
to the decorative film that permits the low-adhesion release liner
to be peeled away without disrupting that bond. Once the
installation process is completed, the cover sheet can be peeled
cleanly from the decorative film without disrupting the adhesive
bond between the decorative film and a substrate. In one
embodiment, the cover sheet is an opaque material.
The present invention is also directed to a laminate adapted for
use to decorate a substrate. The laminate includes a layer of
pre-mask material comprising a cover layer and a layer of removable
structured pressure sensitive adhesive firmly adhered to one
surface of the cover layer. Display lengths of decorative film are
provided having opposite major surfaces and a layer of adhesive
along one of the major surfaces. A release liner is releasably
adhered to the pre-mask by the removable structured pressure
sensitive adhesive on the cover layer and by the adhesive on the
decorative film.
In one embodiment, the display lengths of decorative film have
different predetermined shapes and lengths formed by a computer
operated tape applicator that are applied to the first surface of
the release liner by the tape applicator in a predetermined
pattern. The display lengths can also be prepared manually. The
layer of removable structured pressure sensitive adhesive is
adhered over the outer major surfaces of the display lengths of
decorative film adhered to the release liner and to the release
liner around the display lengths of decorative film.
The present invention is also directed to a method for making a
laminate adapted for use to decorate a substrate. The method
includes the steps of providing a layer of pre-mask material
comprising a cover layer and a layer of removable structured
pressure sensitive adhesive firmly adhered to one surface of the
cover layer. A supply length of decorative film is provided. The
decorative film has an adhesive along a second major surface. A
release liner having opposite first and second major surfaces is
also provided. The first major surface of the release liner is
adapted to be releasably adhered to by the removable structured
pressure sensitive adhesive on the cover layer and by the adhesive
on the decorative film.
In one embodiment, a tape applicator is provided that is adapted to
form display lengths of tape of different lengths and end shapes
from the supply length of tape and to apply the display lengths of
the tape at different precise locations on a surface along an
application plane with longitudinal edges of the display lengths of
tape extending along predetermined edge locations. The release
liner is supported with the first major surface in the application
plane. This process can also be performed manually.
The tape applicator forms display lengths of decorative film of
predetermined shapes and lengths from the supply length of
decorative film and applies those display lengths of decorative
film to the first surface of the release liner in a predetermined
pattern with longitudinal edges of the display lengths of tape
extending along predetermined edge locations. The layer of
removable structured pressure sensitive adhesive is adhered to the
first major surfaces of the display lengths of decorative film and
to the release liner around the display lengths of decorative
film.
In another embodiment, the display lengths of tape can be applied
via a tape applicator (or manually) directly to the structured
pressure sensitive adhesive of the pre-mask. The layer of release
liner is subsequently applied over the pressure sensitive adhesive
and the structured pressure sensitive adhesive.
In one embodiment, the method includes the steps of removing the
release liner from the layers of adhesive included in the display
lengths of decorative film and from the removable structured
pressure sensitive adhesive included in the layer of pre-mask
material. The layers of adhesive included in the display lengths of
decorative film and in the layer of pre-mask material are placed on
a substrate with the display lengths of decorative film at a
desired location along the substrate. Air is pressed out from
between the layers of adhesive included in the display lengths of
decorative film and the substrate. The pre-mask material is removed
to expose the display lengths of decorative film adhered to the
substrate.
In another embodiment, a lubricating liquid is used to wet the
substrate and/or the layers of adhesive included in the display
lengths of decorative film and the layer of structured adhesive on
the pre-mask material and the substrate before the step of placing
the layers of adhesive included in the display lengths of
decorative film and the layer of pre-mask material on the
substrate. A portion of the lubricating liquid and/or entrained air
is pressed out from between the layers of adhesive included in the
display lengths of decorative film and the substrate. Most of the
remaining lubricating liquid is allowed to evaporate before the
step of removing the layer of pre-mask material.
BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWING
The present invention will be further described with reference to
the accompanying drawing wherein like reference numerals refer to
like parts in the several views, and wherein:
FIG. 1 illustrates a first embodiment of a laminate made by a
method according to the present invention, which laminate is
adapted for use to decorate a substrate such as a pane or panes of
glass and includes a plurality of display lengths of decorative
film tape adhered to a release liner in a predetermined decorative
pattern, and a layer of pre-mask material (only a fragment of which
is shown) that is adhered over the display lengths of decorative
film and to the release liner in areas not covered by the display
lengths of decorative film tape;
FIG. 2 is an enlarged sectional view taken approximately along line
2-2 of FIG. 1;
FIG. 3 is a fragmentary plan view of the laminate of FIG. 1 after
the release liner has been removed and the display lengths of
decorative film tape and the layer of pre-mask material that is
adhered over the display lengths of decorative film have been
adhered to a substrate;
FIG. 4 is an enlarged fragmentary sectional view taken
approximately along line 4-4 of FIG. 3;
FIG. 5 is a fragmentary plan view of the display lengths of
decorative film tape in the laminate of FIG. 1 after they have been
applied to the substrate and the overlaying layer of pre-mask
material has been removed;
FIG. 6 is an enlarged fragmentary sectional view taken
approximately along line 6-6 of FIG. 5;
FIG. 7 illustrates a second embodiment of a laminate made by a
method according to the present invention, which laminate is also
adapted for use to decorate a substrate such as a pane or panes of
glass and also includes a plurality of display lengths of
decorative film tape adhered to a release liner in a predetermined
decorative pattern, and a layer of pre-mask material (only a
fragment of which is shown) that is adhered over the display
lengths of decorative film and to the release liner in areas not
covered by the display lengths of decorative film tape;
FIG. 8 is an isometric view of a tape applicator that can be used
in the method according to the present invention, in which view a
tape head included in the applicator is in a first position;
FIG. 9 is an isometric view of the tape applicator of FIG. 8 in
which the tape head is in a second position while applying
decorative film tape to a sheet of release liner in the method
according to the present invention;
FIG. 10 is an enlarged isometric fragmentary view taken
approximately along line 10-10 in FIG. 8 which shows an x-axis
actuator, a y-axis actuator, a rotary actuator, the tape head and a
support arm for the rotary actuator included in the tape applicator
of FIG. 8;
FIG. 11 is an enlarged fragmentary isometric view of the tape
applicator of FIG. 8 showing the tape head rotated around a z-axis
perpendicular to a planar support surface, the rotary actuator for
rotating the tape head around that z-axis, and the support arm;
FIG. 12 is an enlarged fragmentary isometric view of a first side
of the tape head of FIG. 8;
FIG. 13 is an enlarged fragmentary isometric view of the first side
of the tape head of FIG. 8;
FIG. 14 is an enlarged fragmentary isometric view of a second side
of the tape head of FIG. 8 opposite its first side;
FIG. 15 is an enlarged fragmentary view of the first side of the
tape head of FIG. 8 as the tape head starts to apply the decorative
film tape to the sheet of release liner;
FIG. 16 is an enlarged fragmentary view of the first side of the
tape head of FIG. 8 as a first cutter cuts a discrete length of the
decorative film tape being applied to the sheet of release liner
from a supply length of the decorative film tape carried on the
tape head;
FIG. 17 is an enlarged fragmentary view of the first side of the
tape head of FIG. 8 as it finishes applying the cut discrete length
of decorative film tape to the sheet of release liner;
FIG. 18 is an enlarged fragmentary isometric view of the second
side of the tape head of FIG. 8, illustrating a second cutter of
the tape head as it cuts the discrete length of decorative tape
that was previously applied to the sheet of release liner;
FIG. 19 is a top view of a first discrete length of decorative film
tape applied to a surface of the sheet of release liner,
illustrating a sequence of cuts that can be made in that first
discrete length of tape by the second cutter of the tape head;
FIG. 20 is a top view of the first discrete length of decorative
film tape applied to the release liner as illustrated in FIG. 19
with a scrap portion of that first discrete length of decorative
film formed by the cuts illustrated in FIG. 19 removed from the
release liner;
FIG. 21 is a top view of a second discrete length of tape applied
to the release liner illustrated in FIGS. 19 and 20 over the top of
the first discrete length of decorative film tape after the scrap
portion of that first discrete length of decorative film tape has
been removed as illustrated FIG. 20, which FIG. 21 illustrates a
sequence of cuts that can be made in the second discrete length of
tape by the second cutter of the tape head; and
FIG. 22 is a top view of the second discrete length of decorative
film tape applied to the release liner as illustrated in FIG. 21
with a scrap portion of the second discrete length of decorative
film tape formed by the cuts illustrated in FIG. 21 removed from
the release liner to provide aligned closely spaced ends on
adjacent parts of first and second display lengths of decorative
film tape.
FIG. 23 illustrates an alternate embodiment of a laminate for use
to decorate a substrate such as panes of glass, made by a method
according to the present invention.
FIG. 24 is a side sectional view illustrating the structured
adhesive of the alternate laminate of FIG. 23.
DETAILED DESCRIPTION OF THE INVENTION
Referring now to FIGS. 1 and 2 of the drawing there is illustrated
a laminate 500 made by a method according to the present invention,
which laminate 500 is adapted for use to decorate a substrate such
as a pane or panes of glass in a window, a door, or a mirror. The
laminate 500 includes a plurality of display lengths 502 of
decorative film tape each (see FIG. 2) comprising a length of
decorative film 514, which display lengths 502 of decorative film
tape are adhered to a major surface of a release liner 508 in a
predetermined decorative pattern by layers 509 of pressure
sensitive adhesive included in the display lengths 502 of
decorative film tape; and a layer of pre-mask material 510
comprising a cover sheet or layer 511 and a layer 512 of removable
adhesive firmly adhered to one surface of the cover layer 511 that
has its surface opposite the cover layer 511 adhered to outer major
surfaces of the display lengths of decorative film 514 opposite the
release liner 508, and to the major surface of the release liner
508 in areas not covered by the display lengths 502 of decorative
film tape. Only a fragment of the layer of pre-mask material 510 is
illustrated in FIG. 1, however that layer of pre-mask material 510
is typically coextensive with the release liner 508 and extends
over all of the display lengths 502 of decorative film tape. The
pre-mask material 510 can be opaque, translucent or transparent.
The layer 512 can optionally be a structured adhesive, as discussed
hereinafter.
The release liner 508 to which the display lengths 502 of
decorative film tape are adhered is of a polymeric material (e.g.,
polyester, polyethylene, or polypropylene or other smooth polymer
film 0.001 to 0.010 inch or 0.003 to 0.025 cm thick having a
release coating (e.g., a coating containing silicone) to provide
releasable adhesion with the layers 509 and 512 of adhesive in the
display lengths 502 of decorative film tape and in the layer of
pre-mask material 510, respectively.
The length of decorative film 514 in each display length 502 of
decorative film tape can have grooves, vapor coating and/or other
structure along its outer major structured surface opposite the
layer 509 of pressure-sensitive adhesive along its other major
surface so that the decorative film 514 visually simulates
decorative glass, such as glass with a single bevel, beveled edges,
or with a central groove along its length (e.g., a V shaped
groove), or with a leaded appearance, or with a textured surface,
or visually simulate a glass related structure such as metal came
(e.g., the pieces of optical film described in U.S. Pat. No.
5,840,407 issued Nov. 24, 1998, the content whereof is hereby
incorporated herein by reference). Tapes including a length of the
type of optical film disclosed in U.S. Pat. No. 5,840,407 and a
layer of pressure sensitive adhesive along one major surface are
commercially available as 3M.RTM. brand Accentrim.TM. Tape, series
B200 (V-groove tape) and series B 100 (edge bevel tape), from 3M
Company, St. Paul, Minn.
Other decorative or visibly distinctive films that can be used in
the decorative film tape include multi-layer optical films,
composite decorated graphics, microreplicated structured graphics,
decorative films other than v-groove and edge bevel structures,
reflective sheeting and films made with glass beads, and the like.
Additional decorative or visibly distinct films include a
decorative birefringent multi-layer film is available from 3M
Company, St. Paul, Minn., under the trade designation "Radiant
Light Film" that is described in U.S. Pat. No. 5,882,774; or the
vinyl films also available from 3M Company, that can be applied to
glass panes to form graphics that appear to have been etched or
sand-blasted into the glass at a fraction of the cost of actual
etching or sand blasting. These vinyl films, typically plasticized
poly(vinyl chloride), are marketed as Scotchcal.RTM. (trade mark)
Series 7725 special effects films. Among these, Scotchcal.RTM.
(trade mark) 7725-314 Dusted Crystal Film gives the appearance of
etched glass, and Scotchcal.RTM. (trade mark) 7725-324 Frosted
Crystal Film gives the decorative appearance of sand-blasted glass.
Each of these special effects vinyl films bears a layer of
aggressive pressure-sensitive adhesive and a low-adhesion carrier
web that protects the adhesive. The pressure-sensitive adhesive is
selected to form strong bonds to the substrate 518, such as for
example to glass.
Preferably the layer of pre-mask material 510 allows transmission
of moisture vapor between its major surfaces by means, including,
but not limited to, being vented by passageways 516 through the
cover layer 511 and the layer 512 of adhesive between their major
surfaces, (e.g., the layer of pre-mask material described in U.S.
Pat. No. 5,749,994 issued May 12, 1998, the content whereof is
hereby incorporated herein by reference).
Alternatively, the layer of pre-mask material 510, rather than
being perforated, could be selected to allow passage of moisture to
facilitate drying of a substrate to which the display lengths 502
of decorative film tape are adhered. As used herein, "dry" or
"drying" means the elimination of most of the moisture by
evaporation. Complete elimination of all moisture is not required.
Suitable materials for the cover layers 511 in such layers of
pre-mask material (which may not need to be transparent or
translucent for some applications) could be polymers, paper,
cellulose, non-woven fiber or other woven material; and the layers
512 of removable adhesive could be formed from randomly laid
adhesive strands between which strands spaces are left that permit
the passage of moisture.
FIGS. 23 and 24 illustrated an alternate laminate 600 made
generally by the method of the present invention. As discussed in
connection with FIGS. 1 and 2, the laminate 600 includes a
plurality of display lengths 602 of decorative film 614.
The decorative film 614 is adhered to the release liner 608 by
layers 609 of pressure sensitive adhesive. The pre-mask material
610 includes a structured adhesive 612 firmly adhered to at least a
portion of cover layer 611. The structured adhesive 612 is adhered
to outer major surfaces of the display lengths 602 of decorative
film 614 opposite the release liner 608, and to the portions of the
major surface of the release liner 608 not covered by the display
lengths 602 of decorative film 614. Only a fragment of the layer of
pre-mask material 610 is illustrated in FIG. 23, however that layer
of pre-mask material 610 is typically coextensive with the release
liner 608 and extends over all of the display lengths 602 of
decorative film tape. Optionally, the release liner 608 can be
slightly larger than the pre-mask material 610 and the structured
adhesive 612.
The structured adhesive 612 is coated, applied and/or processed to
have a plurality of passageways or channels 616. At least a portion
of the passageways 616 extend to one or more edges 619 of the
structured adhesive layer 612. The passageways 616 permit
transmission of air and moisture vapor out past the edges 617 of
the covering sheet 611.
The passageways 616 may extend the entire thickness of the
structured adhesive layer 612, or some portion thereof. That is,
the passageways 616 may have a cross-sectional dimension along a
z-axis equal to the spacing between the cover sheet 611 and the
release liner 608. Alternatively, the passageways 616 have a
cross-sectional dimension (e.g., diameter) less than the spacing
between the cover sheet 611 and the release liner 608.
In the illustrated embodiment, the pre-mask material 610 is opaque,
although transparent or translucent materials can also be used. The
thickness of the decorative film 614 creates protrusions or ridges
that are visible along the outer major surface 615 of the cover
layer 611. Consequently, the user knows the location of the display
lengths 602 even though the cover layer 611 is opaque. The outer
major surface 615 of the cover layer 611 is preferably printable so
that installation instructions and other information can be printed
thereon.
For the premask material 610 to function well in this application,
the adhesive layer 612 should have aggressive enough adhesion to
adhere to the structured surface of the decorative film 614. Some
decorative films, such as v-groove tape commercially-available from
3M Company of St. Paul, Minn. under the trade designation B200
Accentrim.TM., have a significant surface topology which is
challenging for premask materials 612 to adhere to. The necessary
level of adhesion of the premask to the decorative film 614 is
dependent on the type of graphic (surface topology), the type of
adhesive on the graphic, and the type of release liner 608 on the
laminate 600. The adhesive layer 612 must adhere well enough to
effectively permit removal of the decorative film 614 from the
release liner 608 prior to the installation process.
The adhesion of the adhesive layer 612 to the decorative film 614
must also be strong enough to withstand the installation process
which currently involves contact with a significant amount of soapy
water or other lubricating liquid. The premask material 610 should
not release from the decorative film 614 until the installation
process is complete to prevent misalignment of the display lengths
602. The adhesion must be low enough to permit effective removal of
the premask material 610 after the decorative film 614 has been
installed on the substrate 518 (window, door, etc) while the
display lengths 602 remain attached to the substrate 518. The
adhesion of the premask material 610 also should be relatively
independent of storage conditions and length of time it is in
contact with the decorative film 614.
The passageways 616 can form a regular or an irregular pattern. The
passageways can be linear or curved. For example, the passageways
616 can be arranged in a variety of patterns, including regular
patterns such as rectangular grid patterns, diamond grid patterns,
a plurality of parallel passageways, and combinations thereof.
Although FIG. 24 illustrates the passageways as being generally
rectangular, the actual shape of the passageways may vary depending
upon the nature of the adhesive 612 used, the method of applying
the adhesive to create the required structure, and a variety of
other variables. The cross-sectional shape of the passageways 616
is not critical and can be trapezoidal, triangular, rectangular,
spherical, curvilinear or any approximation of these shapes or
alternatively, irregular shapes.
Pattern coated adhesives, embossed adhesives, or a variety of other
adhesive structures can also be used to form the passageways 616 in
the structured adhesive 612. The density of passageways 616 can
range from about 3 per centimeter to about 71 per centimeter. In
one embodiment, the passageways 616 have a height relative to the
liner 608 of about 15 to about 45 micrometers and a width of about
50 micrometers to about 200 micrometers. In this embodiment, the
cross-sectional area of the passageways is preferably about 1000
square micrometers to about 10,000 square micrometers.
As used herein, "structured adhesive" refers to an adhesive layer
having a plurality of passageways or channels, at least a portion
of which extend to an edge thereof. The structured adhesive is
typically formed on tooling with structural features that are the
mirror image of the desired passageways. Since the structured
adhesive can change and flow after leaving the tooling, reference
to specific shapes, dimensions and other features of the structured
adhesive are typically made with respect to the tooling.
The structured adhesives disclosed in U.S. Pat. No. 6,197,397
(incorporated by reference), assigned to 3M Innovative Properties
Company, are suitable for use in the present invention. Another
approach to forming a structured adhesive suitable for use in the
present invention is disclosed in U.S. Pat. No. 6,524,649
(incorporated by reference), (see also PCT WO 02/13980). This
application discloses the use of a structure release liner that
embosses its structure into the adhesive layer. When the release
liner is removed, the passageways in adhesive layer remain
substantially intact. U.S. Pat. No. 6,872,268 (incorporated by
reference), discloses a variety of structured adhesives.
In addition to groove patterns, passageways can also be provided by
discontinuous adhesive layers, provided, for example, by the
application of adhesive material in stripes, dots, or other like
patterns. Passageways may also be provided by use of adhesive
microspheres or nonadhesive particulates incorporated into adhesive
layers. Roughened adhesive layers, wherein the adhesive surface
contains random bumps or other protrusions of adhesive material,
can also provide passageways. Bumps or other protrusions can also
be added to adhesive layers by printing or otherwise depositing
adhesive or nonadhesive materials onto previously formed adhesive
layers or by applying an adhesive over an adhesive or nonadhesive
material (which may be in the shape of dots, strings or other types
of protrusions).
Passageways may also be provided in the adherent layer by use of
open-structured materials such as open structured adhesives and
open structured adhesive sublayers. As used herein, the term open
structured material refers to a material which, when placed between
two surfaces, holds such surfaces apart while also providing an
open path suitable for fluid flow between the spaced apart
surfaces. Open structures can be provided by, for example, fibrous
or porous adhesives. Adhesives provided in the form of blown
microfibers can be used to provide an open structured adhesive
layer having significant void space for fluid flow. Multi-layer
adhesive systems are also contemplated. For example, an open
structured sublayer can be attached to a major surface of a film
backing, with a porous or otherwise air transmissive adhesive layer
attached to the sublayer. This would allow air in interfacial
airspaces to flow through the adhesive layer, into the open
structured sublayer, and along the sublayer to an edge of the film.
Suitable materials for the sublayer include blown microfiber
structures and open celled foam materials.
A commercially available structured adhesive is available from 3M
Company of St. Paul, Minn. under the trade designation "Comply". A
suitable pre-mask 610 with a structured adhesive is available from
3M Company of St. Paul, Minn. under the product designation
VCC8198. Non-limiting examples of adhesives that can be used for
the present structured adhesive include pressure sensitive
adhesives, hot melt or heat activated adhesives that are pressure
sensitive at the time of application such as pressure sensitive
adhesives disclosed in U.S. Pat. No. 4,994,322 (Delgado et al.);
U.S. Pat. No. 4,968,562 (Delgado); EPO Publication 0 570 515; EPO
Publication 0 617 708; pressure sensitive adhesives disclosed in
U.S. Pat. Nos. 5,296,277 and 5,362,516 (both Wilson et al.), U.S.
Pat. No. 5,141,790 (Calhoun et al.), and U.S. Pat. No. 5,795,636
(Keller et al.), all incorporated by reference and any other type
of pressure sensitive adhesive disclosed in Satas, et al., Handbook
of Pressure Sensitive Adhesives, 2nd Ed. (Von Nostrand Reinhold,
N.Y., 1989), the disclosure of which is incorporated by
reference.
The present structured adhesive 612 can be used with a variety of
cover layers 611, such as polymers, paper, cellulose, non-woven
fiber or other woven materials. In one embodiment, the structured
adhesive 612 is used in combination with the perforated cover sheet
511 of FIG. 1.
The laminate 600 is installed using the method discussed in
connection with FIGS. 3-6. The passageways 616 in the structured
adhesive 612 facilitates the removal of air (and lubricating liquid
when used) between the cover layer 611 and the display lengths 602,
and the substrate 518 (see FIG. 4). The passageways 616 also
facilitate the removal of lubricating liquid vapor during the
drying step prior to the removal of the cover sheet 611.
In one embodiment, the laminates 500 and 600 are assembled
manually. Various fixtures and/or templates can be used to cut the
decorative film to the required lengths and shapes, and to
accurately position the decorative film on the release liner and/or
the pre-mask. For example, the fixtures and/or templates can be
used to position the decorative film in the desired configuration
prior to attaching the release liner and/or the pre-mask. In one
embodiment, the assembly of pre-mask, decorative film, release
liner and adhesive layers is removed from the fixture and/or
template and laminated using heat and/or pressure. In another
embodiment, the assembly can be laminated while still located on
the fixture and/or template.
Generally, the method according to the present invention for making
the laminates 500 and 600 can comprise using a tape applicator 10
shown in FIGS. 8 through 18. To simplify the discussion of the
present method, reference will be made to the laminate 500,
although the method is equally applicable to the laminate 600.
FIGS. 8 through 18 teach a method to form and apply the display
lengths 502 of decorative film tape to the surface of the release
liner 508 in the predetermined pattern, and then adhering the layer
of removable adhesive 512 included in the layer of pre-mask
material 510 over the outer major surfaces of the display lengths
502 of decorative film tape adhered to the to the release liner 508
and to the portions of the release liner 508 around those display
lengths 502 of decorative film tape which can be done manually or
with a laminating machine.
That laminate 500 can then be provided to a person such a homeowner
who can decorate a substrate 518, such as a surface of a glass
sheet in a window surrounded by a frame 520 (see FIGS. 3, 4, 5, and
6), by removing the release liner 508 from the layers of adhesive
509 included in the display lengths 502 of decorative film tape in
the laminate 500 and from the portions of the layer of removable
adhesive 512 included in the layer of pre-mask material 510 that
are exposed around the display lengths 502 of decorative film tape;
placing the then exposed layers of adhesive 509 and 512 included in
the display lengths 502 of decorative film tape and in the layer of
pre-mask material 510 at a desired location on the substrate 518
(FIG. 3); pressing out air from between the substrate 518 and the
layers of adhesive 509 included in the display lengths 502 of
decorative film tape that have their outer major surfaces adhered
to the layer of adhesive 512 included in the layer of pre-mask
material 510; and then removing the layer of pre-mask material 510
to leave the display lengths 502 of decorative film tape adhered to
the substrate 518 in the predetermined decorative pattern as
illustrated in FIGS. 5 and 6.
When, as is preferred, the cover layer 511 and the layer of
adhesive 512 on the cover layer 511 allow moisture vapor to pass
between the surfaces of the layer of pre-mask material 510; the
method can further include the step of using a lubricating liquid
to wet the layers of adhesive 509 and 512 included in the display
lengths 502 of decorative film tape and in the layer of pre-mask
material 510, and to wet the substrate 518 before the step of
placing the exposed layers of adhesive 509 and 512 included in the
display lengths 502 of decorative film tape and in the layer of
pre-mask material 510 on the substrate 518. This allows sliding the
exposed layers of adhesive 509 and 512 included in the display
lengths 502 of decorative film tape and in the layer of pre-mask
material 510 along the substrate 518 for a short time after they
are positioned there (i.e., 1 to 5 minutes) to precisely position
the display lengths 502 of decorative film tape at a desired
position along the substrate 518.
The lubricating liquid should then be allowed to substantially dry
before the removing step although it is not necessary for the
lubricating liquid to completely evaporate. The pressing step
should include also pressing out lubricating liquid from between
the layers of adhesive 509 included in the display lengths 502 of
decorative film tape and the substrate on which they are
positioned, during which pressing the layer of pre-mask material
510 protects the outer major surfaces of the display lengths 502 of
decorative film from damage. More specifically, the substrate or
glass sheet 518 to which the display lengths 502 of decorative film
tape are to be attached should be cleaned (e.g., with a liquid
glass cleaner), and the wetting a lubricating liquid or solution
(e.g., 1/2% (by weight) dishwashing detergent in water) from a
squirt bottle should then be used to wet the layers of adhesive 508
and 512 included in the pieces of decorative film tape and in the
layer of pre-mask material 510 and to wet the substrate 518.
FIG. 7 illustrates an alternate embodiment of a laminate 600 made
by a method according to the present invention, which laminate 600
is adapted for use to decorate a substrate such as a pane or panes
of glass in a window, a door, or a mirror. The laminate 600
includes a plurality of display lengths 502 of the decorative film
tape described above each adhered to a major surface of a sheet of
the release liner 508 described above in a predetermined decorative
pattern by layers 509 of pressure sensitive adhesive included in
the display lengths 502 of decorative film tape; and a layer of the
pre-mask material described above that is adhered to outer major
surfaces of the display lengths 502 of decorative film 514 opposite
the release liner 508, and to the major surface of the release
liner 508 in areas not covered by the display lengths 502 of
decorative film tape. Only a fragment of the layer of pre-mask
material 510 is illustrated in FIG. 7, however that layer of
pre-mask material 510 is coextensive with the release liner 508 and
extends over all of the display lengths 502 of decorative film
tape. The display lengths 502 of decorative film tape in the
laminate 600 can be transferred to a substrate using the method
described above with reference to the laminate 500.
The tape applicator 10 for forming and applying display lengths 502
of decorative film tape to the release liner 508 in predetermined
patterns including the patterns illustrated in FIGS. 1 through 7
can be the tape applicator 10 described in U.S. Pat. No. 6,571,849,
the content of which is incorporated herein by reference.
Generally, as is seen in FIGS. 8 through 18, the tape applicator 10
described in that application comprises a tabletop 21 having a
planar support surface 22 adapted for supporting a sheet material
such as the release liner 508 with its major surface opposite the
support surface 22 in an application plane defined by the tape
applicator 10; and a tape head 100 comprising a frame 106 having a
leading end 107 and an opposite trailing end 115. The tape
applicator 10 also includes a computer operated assembly adapted
for moving the frame 106 of the tape head 100 over the support
surface 22 in any predetermined pattern with that pattern including
a plurality of straight line movements comprising straight line
movements with the leading end 107 of the frame 106 leading. The
tape head 10 further includes an application member or roller 120
having a cylindrical application surface 121; means mounting the
application member 120 on the frame 106 adjacent its trailing end
115 for movement between an application position with its
application surface 121 along the application plane, and a release
position with its application surface 121 spaced from or above the
application plane. Means are provided on the frame 106 for
supporting a supply length 92 of the decorative film tape and for
guiding the supply length 92 of decorative film tape along a path
extending over the application surface 121 with the edges of the
decorative film tape along the path being parallel to the direction
of movement of the frame 106 during the straight line movements
with the leading end 107 of the frame 106 leading. Severing means
or a first cutter 116 is provided on the frame 106 along the path
for severing a discrete length 501 of the decorative film tape
being applied to the release liner 508 along the application plane
from the supply length 92 of decorative film tape moving along the
path, as are means on the frame 106 for advancing the supply length
92 of decorative film tape along the path to move a newly severed
end of the supply length 92 of decorative film tape formed by the
first cutter 116 to the application surface 121. Cutting means or a
second cutter 154 including a circular blade 156 having a sharp
elongate circular cutting edge 155 about its periphery is mounted
on the frame 106 for rotation and for movement between an
application position with its cutting edge 155 along the
application plane at which it can cut through a discrete length 501
of decorative film tape along the release liner 508, and a release
position with its cutting edge 155 spaced from or above the
application plane.
To form the laminate 500 the release liner 508 is supported on the
support surface 22 to position its major surface opposite the
support surface 22 in the application plane. Discrete lengths 501
of the decorative film tape are applied to the release liner 508 in
a predetermined pattern typically (but not necessarily) with
portions of certain of the discrete lengths 501 of decorative film
tape overlapping each other by, for each discrete length 501, (1)
positioning an end portion of the supply length 92 of decorative
film tape along the application surface 121 of the application
member 120 when the application member 120 is in its release
position, (2) moving the application member 120 to its application
position and moving the frame 106 of the tape head 100 over the
application plane in straight line movement with the leading end
107 of the frame 106 leading to pull the supply length 92 of
decorative film tape along the path and apply a straight discrete
length 501 of the decorative film tape to the surface of the
release liner 508 as the application member 120 moves over it, and
(3) operating the severing means or first cutter 116 to form an end
96 for the applied discrete length 501 of decorative film tape and
a new end for the supply length 92 of decorative film tape. The
tape applicator 10 is then used to cut the discrete lengths 501 of
decorative film tape applied on the release liner 508 with the
second cutter 154 to form new ends on those applied discrete
lengths 501 of decorative film tape at predetermined locations
along the surface of the release liner 508, including aligned
closely spaced ends at any overlapped portions of the applied
discrete lengths 501 of decorative film tape, which cutting with
the second cutter 154 forms the display lengths 502 of decorative
film tape from the discrete lengths 501 of decorative film tape
applied to the release liner 508. Such cutting is done by moving
the frame 106 of the tape head 100 over the application plane along
predetermined paths with the cutter 154 in its cutting position so
that the cutting edge 155 of the cutter 154 traverses the applied
discrete lengths 501 of decorative film tape. Scrap portions of the
applied discrete lengths 501 of decorative film tape resulting from
cutting those applied discrete lengths 501 of decorative film tape
to form the new ends and thereby the display lengths 502 of
decorative film tape are then manually removed from the release
liner 508; and the layer of removable adhesive 512 included in the
layer of pre-mask material 510 is manually adhered over the outer
major surfaces 513 of the display lengths 502 of decorative film
tape adhered to the release liner 508 and is also adhered to the
release liner 508 around those display lengths 502 of decorative
film tape, completing the laminate.
Following, with reference to FIGS. 8 through 18 is a more detailed
description of the tape applicator 10 that was described in U.S.
Pat. No. 6,571,849. The tape applicator 10 includes a frame 12 for
holding the tabletop 21 that has the planar support surface 22. The
tabletop 21 can be tilted as illustrated to allow an operator to
easily place a sheet of material such as the release liner 508 on
the support surface 22. The tape applicator 10 may include a vacuum
system (not shown) for holding the sheet material or release liner
508 stationary on the support surface 22. Such a vacuum system
could include small spaced openings through the tabletop 21 and
support surface 22, which small spaced openings communicate with a
source of air pressure well below atmospheric air pressure (i.e., a
vacuum) beneath the tabletop 21. Alternatively, the release liner
508 could be held stationary on the support surface 22 through the
use of static electricity, or the use of pressure sensitive
adhesive coated tape (e.g., masking tape). The support surface 22
and frame 12 are sized to handle desired sizes of release liners
such as the release liner 508 illustrated, and to support the tape
head 100 and actuators 30, 32, and 34 that are included in means
for moving the tape head over the support surface 22.
The tape applicator 10 defines an x-axis and a y-axis normal to the
x axis, which x and y axes are in a plane parallel to the planar
support surface 22 of the tabletop 21, together with a z-axis that
is perpendicular to the plane defined by the x and y axes. The
tabletop 21 includes a first raised edge 24 parallel to the x-axis
and a second raised edge 26 parallel to the y-axis, and has a
measuring scale 27 along each of those raised edges 24 and 26. A
user can place a sheet of release liner 508 on the support surface
22 with its edges against the raised edges 24 and 26.
The tape applicator 10 includes a support arm 18 for supporting and
moving the tape head 100 to different locations on the tabletop 21.
The support arm 18 extends parallel to the y-axis and moves in a
direction parallel to the x-axis along first slide rods 19a, 19b.
The end of the support arm 18 opposite the first slide rods 19a,
19b includes a leg 54 and a wheel 56 rotatably mounted on the leg
54 that helps to support the support arm 18 above the tabletop 21
while allowing the support arm 18 to move along the support surface
22 in a direction parallel to the x-axis. The support arm 18 also
includes second slide rods 60a, 60b, which are located on the side
of the support arm 18 adjacent the tabletop 21 and extend in a
direction parallel to the y-axis. The tape head 100 can move in a
direction parallel to the y-axis along the slide rods 60a, 60b of
the support arm 18.
FIG. 8 illustrates the tape head 100 positioned in a "home
position" above the tabletop 21. This is where the tape head 100 is
normally located when an operator places a sheet of release liner
508 on the tabletop 21. FIG. 9 illustrates the tape head 100 moved
to a different location, at which it is applying a discrete length
501 of decorative film tape to the sheet of release liner 508 as
the tape head 100 moves over the support surface 22. To move the
tape head 100 to a new location on the support surface 22, the tape
head 100 may need to move in directions parallel to both the x-axis
and the y-axis. To move the tape head 100 in a direction parallel
to the x-axis of the tabletop 21, the support arm 18 slides along
the first slide rods 19a and 19b. To move the tape head 100 in a
direction parallel to the y-axis, the tape head moves along the
second slide rods 60a, 60b that are located on the side of the
support arm 18 adjacent the support surface 22. The tape applicator
can move the tape head 100 to a first location along the support
surface 22, adhere an end portion of the supply length 92 of
decorative film tape to the sheet of release liner 508 on the
support surface 22, and then apply a discrete length 501 of the
decorative film tape to the sheet of release liner 508 on the
support surface 22 by moving the tape head 100 in a straight line
to a second location along the support surface 22.
FIG. 10 illustrates the x-axis actuator 30 by which the tape
applicator 10 moves the tape head 100 in a direction parallel to
the x-axis along the support surface 22, the y-axis actuator 32 by
which the tape applicator 10 moves the tape head 100 in a direction
parallel to the y-axis along the support surface 22, and the z-axis
actuator 34 for rotating the tape head 100 around an axis parallel
to the z-axis. The x-axis actuator 30 includes a motor 31, a ball
screw 40, an end block 41 that contains a bearing for the ball
screw 40 and receives the ends of the first slide rods 19a, 19b,
and a car 46 for moving the support arm 18 along first slide rods
19a, 19b. The support arm 18 is attached to the car 46 by a plate
42. As the motor 31 turns the ball screw 40, the ball screw rotates
moving the car 46 in a direction parallel to the x-axis along the
first slide rods 19a, 19b. As the car 46 moves, the support arm 18
and tape head 100 move with the car 46 across the support surface
22. Any commercially available x-axis actuator capable of obtaining
the conditions described herein may be used, such as the Linear
System Actuator, sold under the trade name Thomson, part number
2EB16FTBTL, which is commercially available from Thomson
Industries, Inc., Port Washington, N.Y. The motor 31 for the x-axis
actuator is can be a step motor (e.g., the step motor sold under
the trade name Compumotor, part number CP*S57-102-MO-25, which is
commercially available from Braas Company, St. Paul, Minn.
The y-axis actuator includes the motor 33, a ball screw 62, an end
block 61 that contains a bearing for the ball screw 62 and receives
the ends of the first slide rods 60a, 60b, and a car 68 for moving
the tape head 100 along support arm 18 in a direction parallel to
the y-axis. The tape head 100 is attached to the car 68 by a plate
64. A portion of the support arm 18 is cut away to illustrate the
y-axis actuator 32. As the motor 33 turns the ball screw 62, the
car 68 moves along the second slide rods 60a and 60b in a direction
parallel to the y-axis. As the car 68 moves, the tape head 100
moves with the car 68 along the support arm 18. Any commercially
available y-axis actuators capable of obtaining the conditions
described herein may be used, such as Linear System Actuator sold
under the trade name Thomson, part number 2RBM160DMKL1300, which is
commercially available from Thomson Industries, Inc., Port
Washington, N.Y. The motor 61 for the y-axis actuator can be a step
motor (e.g., the step motor sold under the trade name Compumotor,
part number CP*S57-51-MO-25, which is commercially available from
Braas Company, St. Paul, Minn.
The rotary actuator 34 for rotating the tape head 100 around an
axis parallel to the z-axis is mounted on the plate 64. The rotary
actuator 34 includes a motor 82, a gear reducer 80, and a flange 86
located between the motor 82 and gear reducer 80. The rotary
actuator 34 is attached to the tape head 100 by a rotary shaft
projecting from the actuator that has an end portion fixed in a
bracket 105 (not seen in this view, see FIGS. 12 and 14) on the
frame 106 of the tape head 100. The motor 82 is a step motor (e.g.,
the step motor sold under the trade name Compumotor, part number
S83*135-MO-S, which is commercially available from Braas Company,
St. Paul, Minn.). The gear reducer 80 is an in-line gear reducer
(e.g., an in-line gear reducer with a twenty-five to one ratio so
that every time the motor 82 turns twelve and a half revolutions,
the gear reducer 80 will turn the tape head 100 180.degree. around
an axis parallel to the z-axis, such as the 25 to 1 gear reducer
sold under the trade name Alpha, part number
LP070M02-25-1/ZETA57-21, which is commercially available from Braas
Company, St. Paul, Minn.
FIG. 11 illustrates the rotary actuator 34 rotating the tape head
100 around an axis parallel to the z-axis. The rotary actuator 34
rotates the tape head 100 around the axis parallel to the z-axis to
position the tape head 100 at different angles on the support
surface or tabletop 21. The tape head 100 can be rotated to a
desired angle by the rotary actuator 34 to allow the second cutter
154 to cut a discrete length 501 of decorative film tape after it
has been applied to the sheet of release liner 508, which is
explained in greater detail below. The rotary actuator 34 is
mounted on the car 68 of the support arm 18. The rotary actuator 34
includes the motor 82 and the gear reducer 80 for rotating the tape
head 100 around an axis parallel to the z-axis. As noted above, the
gear reducer 80 has a shaft extending from it (not seen in this
view), which attaches to and is fixed in the bracket 105 (see FIGS.
12 and 14) mounted on a second side 113 of the frame 106 for the
tape head 100. As the rotary actuator 34 turns the shaft, the tape
head 100 turns with the shaft around an axis parallel to the z
axis.
Details and operation of the tape head 100 are illustrated in FIGS.
12 through 14. The tape head 100 first begins applying a discrete
length 501 of the supply length 92 of decorative film tape to the
sheet of release liner 508 and then, as that discrete length 501 of
decorative film tape is being applied, the tape head 100 cuts the
decorative film tape with the first cutter 116 to form the end of
the discrete length 501 of the decorative film tape being applied
to the release liner 508. An end portion of that discrete length
501 of decorative film tape being applied to the release liner 508
is then applied to the sheet of release liner 508 by the tape head
100 as the tape head 100 continues moving over the sheet of release
liner 508. Next, the tape head 100 cuts the discrete length 501 of
decorative film tape adhered to the sheet of release liner 508 with
the second cutter 154 to form new ends of desired shapes and at
desired locations on the release liner 508 along the applied
discrete length 501 of decorative film tape(e.g., the new ends can
extend in a direction at a right angle to or oblique to the
longitudinal edges of the applied discrete length 501 of decorative
film tape), forming one or more display lengths 502 of decorative
film tape from that discrete length 501 of decorative film tape,
and leaving scrap pieces of that applied discrete length 501 of
decorative film tape at the newly formed ends of the display
lengths 502 of decorative film tape. Those scrap pieces of the
applied discrete length 501 of decorative film tape are then
removed from the sheet of release liner 508, which removal can be
done manually by an operator of the tape applicator 10.
FIG. 12 illustrates a first side 109 of the tape head 100. The
rotary actuator 34 for rotating the tape head 100 around an axis
parallel to the z-axis is not shown. The tape head 100 includes the
frame 106 that has an upper portion 106a and a lower portion 106b.
A tape roll holder 102 and a second tape guide roller 108 are
rotatably mounted on the upper portion 106a. The tape roll holder
102 will receive a roll 90 of the supply length 92 of decorative
film tape that has a release liner 94 releasably adhered along its
coating 509 of pressure sensitive adhesive. The tape roll holder
102 includes a friction clutch 103 to provide back tension on the
supply length 92 of decorative film tape as it unwinds from the
tape roll 90. The tape head 100 also includes a first tape guide
roller 110, a pinch roller 118, a pivotable tape guide 122, the
first cutter 116, the application roller 120, and a liner take-up
roller 136, all mounted on the lower portion 106b of the frame 106.
The first cutter 116 includes a fixed lower blade 112 and a
moveable upper blade 114 that may be pivoted relative to the fixed
blade 112 to sever the decorative film tape. The application roller
120 is rotatably mounted on a bracket 130, which bracket 130 is
mounted on the lower portion 106b of the frame 106 for pivotal
movement about a shaft 133 so that it can be moved by operation of
an air cylinder 131 connected between the bracket 130 and the frame
106 to move the peripheral or application surface 121 of the
application roller 120 adjacent the support surface 22 between an
application position with its application surface 121 along and
biased against a surface such as that of the release liner 508
along the application plane, and a release position with its
application surface 121 spaced above the application plane. The
liner take-up roller 136 includes a friction clutch 138 driven by a
motor 137 through gears in a speed reducer 139 to provide tension
in the release liner 94 as it is wound onto the liner take-up
roller 136. The supply length 92 of decorative film tape moves
along a path from the tape roll holder 102 to the second tape guide
roller 108; then to the nip formed between the first tape guide
roller 110 and the pinch roller 118; then to the pivotal tape guide
122; then between the blades 112 and 114 of the first cutter 116
which are normally spread apart; and then under the peripheral
surface 121 of the application roller 120 which peripheral surface
provides the application surface 121 for applying the decorative
film tape to the release liner 508. The release liner 94 moves
along the portion of that path extending from the tape roll holder
102 to the pivotal tape guide 122 which separates the release liner
94 from the supply length 92 of decorative film tape. After the
release liner 94 is separated from the supply length 92 of
decorative film tape, the release liner 94 winds around the pinch
roller 118 and is taken up by the liner roller 136, as is seen in
more detail in FIG. 15.
After loading a new roll 90 of decorative film tape having the
release liner 94 adhered thereto onto the tape head 100, the
decorative film tape and release liner 94 are threaded through the
tape head 100 along the tape path outlined above. The pinch roller
118 is mounted on the end of a mounting slide 132. The mounting
slide 132 may be slid away from the first tape guide roller 110 to
allow the supply length 92 of the decorative film tape and the
liner 94 to be positioned in the nip between the pinch roller 118
and the first tape guide roller 110. The liner 94 is separated from
the supply length 92 of decorative film tape near the pivotal
decorative film tape guide 122. The liner 94 is then wound around
the pinch roller 118 and wound around the liner roller 136.
FIG. 13 is a partial isometric view of the lower portion 106b of
the frame 106. The decorative film tape winds around the first tape
guide roller 110 between two opposite tape edge guides 104. The
tape edge guides 104 assist in keeping the supply length 92 of
decorative film tape straight just prior to its application to the
release liner 508 by the application roller 120. The supply length
92 of decorative film tape then passes over the pivotal tape guide
122 along a guide surface 124 including two opposite tape edge
guides 128 aligned with the tape edge guides 104 on the first tape
guide roller 110. The tape edge guides 128 also assist in keeping
the supply length 92 of decorative film tape straight just prior to
its application to the release liner 508 by the application roller
120. The release liner 94 is separated from the decorative film
tape at a sharp edge 126 of the guide surface 124 between the two
tape edge guides 128. The guide surface 124 of the pivotal tape
guide 122 can be pivoted to the position best seen in FIG. 13 at
which the guide surface 124 directs the decorative film tape over
the fixed blade 112 of the first cutter 116. The moveable blade 114
is pivoted away from the fixed blade 112 to allow the decorative
film tape to pass between the blades 112, 114 of the first cutter
116. The discrete length 501 of decorative film tape is then
applied to the surface of the release liner 508 by the application
roller 120.
FIG. 14 illustrates the second side 113 of the tape head 100, which
is opposite the first side 109 of the tape head 100 illustrated in
FIG. 12. The rotary actuator 34 for rotating the tape head 100
around the z-axis is not shown. The bracket 105 fixed to the frame
106 is clamped around a rotatable driven shaft (not shown) from the
rotary actuator 34 received in a socket 101 in the bracket 105 to
attach the tape head 100 to the rotary actuator 34. The tape head
100 includes a rotary motor 164 mounted to the lower portion 106b
of the frame 106 for driving the first tape guide roller 110 by
shaft 111 through a one-way clutch bearing (not shown). The one-way
clutch bearing allows the first tape guide roller 110 to rotate
freely during application of a discrete length 501 of the
decorative film tape by movement of the tape head 100, and also
allows the first tape guide roller 110 to be driven by the rotary
motor 164 to advance the new end of the supply length 92 of
decorative film tape to the application roller 120 after the
applied discrete length 501 of decorative film tape has been cut
from the supply length 92 by the first tape cutter 116. The tape
head 100 also includes a first air cylinder 150 attached between
the frame 106 and the moveable blade 114 for actuating the moveable
blade 114 in the first cutter 116. The tape head 100 also includes
the second cutter 154 mounted on the lower portion 106b of the
frame 106. The second cutter 154 includes the circular blade 156
having the elongate sharpened edge 155 extending about its
periphery that is mounted for rotation about its axis on a bracket
158. The bracket 158 is pivotably mounted on the frame 106 by a
pivot shaft 159 and is pivotable by a second air cylinder 160
between the frame 106 and the bracket 158 for movement between a
release position with its cutting edge 155 spaced from (i.e.,
above) the application plane at which release position the second
cutter 154 is positioned when a discrete length 501 of decorative
film tape is being applied to the release liner 508 by movement of
the tape head 100; and an application position with its cutting
edge 155 along the application plane at which the second cutter 154
can be positioned to cut new ends on discrete lengths 501 of
decorative film tape already applied to the release liner 508 by
movement of the frame 106 over the application plane along a
predetermined path so that the cutting edge 155 traverses the
applied discrete length 501 of decorative film tape. The rotary
actuator 34 (not shown) rotates the tape head 100 about the z-axis
to correctly position the blade 156 at a desired angle relative to
the applied discrete length 501 of decorative film tape on the
release liner 508 to allow the blade 156 to cut the applied
discrete length 501 of decorative film tape. Alternatively, the
second cutter 154 could rotate independently of the tape head 100
and thus, not require the entire tape head 100 to rotate.
FIGS. 15 to 18 illustrate portions of the method according to the
present invention for applying display lengths 502 of the
decorative film tape to the release liner 508 in a predetermined
pattern (e.g., the patterns shown in FIGS. 1 and 7) which method
includes applying discrete lengths 501 of the decorative film tape
to the release liner 508 in a predetermined pattern, and then
cutting those discrete lengths 501 of the decorative film tape
after they have been applied to the release liner 508 to form ends
of predetermined shapes and at a predetermined positions on the
release liner 508 along those applied discrete lengths 501 of
decorative film tape, (some of which new ends can be in positions
aligned with and closely spaced from each other) to form one or
more display lengths 502 of the decorative film tape from the
discrete lengths 501 of decorative film tape.
FIG. 15 illustrates the tape head 100 as it begins to apply a
discrete length 501 of the decorative film tape to the surface of
the release liner 508. An end portion of the decorative film tape
has been advanced from the first cutter 116 to a position between
the release liner 508 and the peripheral application surface 121 on
the application roller 120 when that application surface 121 is in
its release position by operation of the motor 164 to rotate the
first tape guide roller 110 through the one way clutch. The
application roller air cylinder 131 is then actuated to move the
application roller 120 to its application position with its
application surface 121 biased against the decorative film tape on
the release liner 508 so that the adhesive layer 509 bonds the
decorative film tape to the release liner 508. The tape head 100 is
then moved over the stationary release liner 508 so that the
decorative film tape is pulled by such movement along the tape path
through the tape head 100 and is applied to the release liner 508
by movement of the application surface 121 along the discrete
length 501 of decorative film tape being applied. The tape roll
holder 102 and the first and second tape guide rollers 110 and 108
then freely rotate (i.e., the first tape guide roller 110 rotates
without rotating the motor 164 because of the one way clutch
between the motor 164 and the first tape guide roller 110).
FIG. 16 illustrates the tape head 100 after a discrete length 501
of the decorative film tape has been applied to the release liner
508 and just after the first cutter 116 has cut that discrete
length 501 of decorative film tape from the supply length 92 of
decorative film tape. The first air cylinder 150 has moved the
moveable blade 114 to contact the fixed blade 112 and thereby
transversely cut the decorative film tape. As the moveable blade
114 is moved to contact the fixed blade 112, the tape guide 122 is
rotated counter clockwise to move the guide surface 124 away from
the blades 114 and 116 because of a ball joint between the moveable
blade 114 and the pivotal tape guide 122 that causes them to move
together. Cutting the applied discrete length 501 of decorative
film tape from the supply length 92 of decorative film tape has
formed a new end on the supply length 92 of decorative film tape
and has also formed a second end 96 on the applied discrete length
501 of decorative film tape which still has a portion D adjacent
that second end 96 yet to be applied to the release liner 508,
which portion D is applied by further movement of the tape head 100
as is illustrated in FIG. 17.
FIG. 17 also illustrates the first air cylinder 150 having moved
the moveable blade 114 out of contact with the fixed blade 112 and
thereby having moved the pivotal tape guide 122 clockwise to
position the guide surface 124 between the blades 114, 112 because
of the connection between the moveable blade 114 and the tape guide
122 to allow the decorative film tape to pass through the first
cutter 116 when the newly cut end of the supply length 92 of
decorative film tape is subsequently advanced to a position along
the application surface 121 on the application roller 120 as was
described above.
FIG. 18 illustrates the second cutter 154 cutting the discrete
length 501 of optical film tape after it has been applied to the
release liner 508 to form at least one display length 502 of
optical film tape. The application roller air cylinder 131 has
moved the application surface 121 on the application roller 120 to
its release position spaced from the surface of the release liner
508. The x-axis and y-axis actuators 30 and 32 have moved the blade
156 to a predetermined position along the applied discrete length
501 of optical film tape, and the rotary actuator 134 (not shown)
has rotated the tape head 100 about an axis parallel to the z-axis
to a desired angle cc relative to the applied discrete length 501
of optical film tape to accurately position the blade 156 of the
second cutter 154 at a desired position and angle relative to the
applied discrete length 501 of optical film tape on the release
liner 508. The x-axis and y-axis actuators 30 and 32 then move the
tape head 100 back and forth in the direction of the orientation of
the blade 156 to cause the blade 156 to cut through the applied
discrete length 501 of optical film tape at the angle .alpha.,
which as illustrated is oblique to the length of the applied
discrete length 501 of optical film tape.
FIGS. 19 through 22 sequentially illustrate, by showing discrete
lengths 501 a and 501b of the decorative film tape applied to the
release liner 508 and sequences of cuts made by the second cutter
154 in those discrete lengths 501 a and 501b of the decorative film
tape, the operation of the tape applicator 10 to form an
intersection 220 between display lengths 502a, 502b, 502c, and 502d
of decorative film tape formed from the first and second discrete
lengths 501a and 501b of the decorative film tape, which display
lengths 502a, 502b, 502c, and 502d of decorative film tape have
straight end surface portions 208, 209, 210, 211, 212, 213, 214,
and 215 aligned with and closely spaced from each other as is
illustrated in FIG. 22.
FIGS. 19 illustrates the first discrete length 501 a of decorative
film tape adhered to the release liner 508 and a sequences of cuts
1-12 that can be made by the second cutter 154 to sequentially form
the straight end surface portions 208, 209, 210, and 211 on new
closely spaced end portions 204a and 205a of the display lengths
502a and 502b of decorative film tape made from that first applied
discrete length 501a of decorative film tape, while leaving a scrap
piece 98 of the applied discrete length 501a of decorative film
tape between those new end portions 204a and 205a. The cuts in the
sequence of cuts made to form the straight end surface portions
208, 209, 210, and 211 on the end portions 204a and 205a are
identified by the reference numerals 1-12 in FIG. 19. The cuts
(i.e., 1,2, and 3 or 4, 5, and 6, etc.) that make one new straight
end surface portion on the discrete length 501a of tape or on the
discrete length 501b of tape are all made along the same straight
line, however the illustrated path of the first and third cuts have
been slightly separated from the second cut (which is along that
straight line) to more clearly indicate the sequence of those
cuts.
The tape head 100 is operated as follows to make the sequences of
cuts 1-12 in the applied discrete length 501a of decorative film
tape adhered to the release liner 508 as is illustrated in FIG. 19.
With the second cutter 154 in its release position in which the
blade 156 is spaced above the first applied discrete length 501a of
decorative film tape adhered to the release liner 508, the tape
head 100 is moved to position the blade 156 at the proper angle and
in the middle of where the first straight end surface portion 208
on the end portion 204a will be formed. The second air cylinder 160
is then actuated to move the blade 156 of the second cutter 154 to
its application position in contact the applied discrete length
501a of decorative film tape. The tape head 100 is then moved
toward the adjacent edge of the tape to make cut 1 at angle .alpha.
(which as illustrated is about 45.degree.) as the blade 156 rotates
and cuts through the first applied discrete length 501a of
decorative film tape. The tape head 100 is then moved in the
opposite direction toward the center of that tape so that the
rotating blade 156 makes cut 2 also at the angle .alpha., and is
then again moved in the opposite direction again toward the edge of
that tape so that the rotating blade 156 makes cut 3 at angle
.alpha.. The second cutter 154 is then moved by the air cylinder
160 to its release position out of contact with the applied
discrete length 501a of decorative film tape while the tape head
100 is moved to position the blade 156 in the middle of where the
end surface 209 on the second end portion 205a will be formed,
which end surface 209 is parallel to the end surface 208 of the end
portion 204a, but off set by a distance "b" (see FIG. 20) for
reasons that will later be explained. The second air cylinder 160
is then again actuated to move the blade 156 of the second cutter
154 to its application position in contact the applied discrete
length 501a of decorative film tape and the tape head 100 is moved
toward the edge of that tape so that the rotating blade 156 makes
cut 4 at angle .alpha., is then moved in the opposite direction
toward the center of that tape so that the rotating blade 156 makes
cut 5 also at the angle .alpha., and is then again moved in the
opposite direction toward the edge of that tape so that the
rotating blade 156 makes cut 6 at angle .alpha.. The second cutter
154 is then again moved by the air cylinder 160 to its release
position with the blade 156 out of contact with the applied
discrete length 501a of decorative film tape adhered to the release
liner 508. The tape head 100 is then rotated through angle .delta.,
which as illustrated is about 90.degree., and starts cutting a
second end surface portion 210 on the second end portion 205a and a
second end surface portion 211 on the first end portion 204a which
is done with the sequence of cuts 7-12 that is performed in
essentially the same manner as the sequence of cuts 1-6 described
above.
Alternatively, a single blade could make a single cut instead of
three individual cuts 1-3, 4-6, 7-9, or 10-12.
FIG. 20 illustrates the scrap portion 98 having a shape similar to
that of a butterfly that is removed from the release liner 508 and
from between the two display lengths 502a and 502b of decorative
film tape made from the discrete length 501a of decorative film
tape adhered to the release liner 508 when the end surface portions
208, 209, 210, and 211 on the new end portions 204a and 205a are
cut by the second cutter 154 as described above. Those end surfaces
208, 209, 210, and 211 are disposed to form V-shaped notches
adapted to receive end portions 204b and 205b cut by the second
cutter 154 as described below with reference to FIGS. 21 and 22 to
form display lengths 502c and 502d of decorative film tape from a
second applied discrete length 501b of decorative film tape adhered
to the release liner 508 transverse to the first applied discrete
length 501a of decorative film tape after the scrap portion 98 was
removed to give a visually pleasing intersection 220 between the
end portions 204a, 205a, 204b, and 205b of those four display
lengths 502a, 502b, 502c, and 502d of decorative film tape as is
illustrated in FIG. 22.
FIGS. 21 illustrates the second discrete length 501b of decorative
film tape applied and adhered by the tape applicator 10 to the
release liner 508 and over the end portions 204a and 205a of the
display lengths 502a and 502b of decorative film tape formed from
the first applied discrete length 501a of decorative film tape with
the longitudinal edges of the second discrete length 501b of
decorative film tape at a 90.degree. angle with respect to the
longitudinal edges of the display lengths 502a and 502b of
decorative film tape formed from the first applied discrete length
501a of decorative film tape and the second discrete length 501b of
decorative film tape extending an equal distance along each of the
display lengths 502a and 502b of decorative film tape. FIG. 21 also
illustrates a sequence of cuts 1-12 that can be made in the second
applied discrete length 501b of decorative film tape after it has
been applied to the release liner 508 and over the end portions
204a and 205a to sequentially form the straight end surface
portions 212, 213, 214, and 215 on the new end portions 204b and
205b of display lengths 502c and 502d of decorative film tape
thereby formed from the second applied discrete length 501b of
decorative film tape. That sequences of cuts 1-12 is essentially
the same as the sequence of cuts 1-12 described above for forming
the end surface portions 208, 209, 210, and 211 on the end portions
204a and 205a of the display lengths 206a and 207a of decorative
film tape made from the first applied discrete length 501a of
decorative film tape, and also leave a scrap piece 99 of the
applied discrete length 501b of decorative film tape between those
new end portions 204b and 205b.
FIG. 22 illustrates the second waste portion 99 (that has the same
shape as the waste portion 98) after it has been removed by a user
from the top of the end portions 204a and 205a on the display
lengths 502a and 502b of decorative film tape and from between the
end portions 204b and 205b of the two display lengths 502c and 502d
formed from the second applied discrete length 501b of decorative
film tape. Removing the second scrap portion 99 from the angled
ends 204a and 205a completes the intersection 220 formed between
the end portions 204a and 205a of the display lengths 502a and 502b
of decorative film tape and the two end portions 204b and 205b of
the display lengths 502c and 502d of decorative film tape. The end
portions 204b and 205b have the same shape as the end portions 204a
and 205a on the display lengths 502a and 502b of decorative film
tape. The straight end surface portions 212 and 214 of the first
end portion 204b and the straight end surface portions 213 and 215
of the second end portion 205b are each disposed at the angle
.alpha.' relative to the length of the second applied discrete
length 501b of decorative film tape.
There is an equal distance "b" between the opposing straight
parallel end surface portions 208-212, 210-214, 209-213, 211-215 of
the end portions 204a, 204b, 205a and 205b that provides space for
thermal expansion of the display lengths 502a, 502b, 502c, and
502d. Without such a space, thermal expansion could cause end
contact and resultant buckling of the display lengths 502a, 502b,
502c, and 502d of decorative film tape. That distance "b" can be
between 0.005 inch and 0.12 inch or 0.013 cm and 0.3 cm, and
preferably is around 0.01 inch or 0.025 cm.
The sequences of cuts 1-6 made by the second cutter 154 to form the
intersections 220 cut through the discrete lengths 501a and 501b of
decorative film tape, but preferably not through the release liner
508, although cuts in the release liner 508 can and do occur. The
release liner 508 can be reinforced at such cuts in it by adhering
a length of pressure sensitive adhesive coated tape over each cut
in the release liner 508 on the surface of the release liner 508
opposite the display lengths 502a, 502b, 502c, and 502d of
decorative film tape formed by those cuts.
The opposed end surface portions 208-212, 210-214, 209-213, 211-215
of the end portions 204a, 204b, 205a and 205b on the display
lengths 502a, 502b, 502c, and 502d are cut to fit together to give
a desired appearance for the intersection 220. Angles .alpha. and
.alpha.', which are both 45.degree. as illustrated (so that the end
surface portions on each end portion are disposed at 90.degree.
with respect to each other) may be changed for a desired appearance
of the intersection. For example, angle .alpha. may be 30.degree.
and angle .alpha.' may be 60.degree., or other combinations of
angles for .alpha. and .alpha.' may be used.
The tape applicator 10 can be used to apply a plurality of discrete
lengths 501 of the decorative film tape to the release liner 508
and to form a plurality of intersections 220 between those discrete
lengths 501 in the manner illustrated in FIGS. 19 through 22 to
form many decorative patterns including the decorative patterns for
the laminates illustrated in FIGS. 1 and 7.
As an example, to form the pattern of display lengths 502 of
decorative film tape illustrated in FIG. 1 the tape applicator 10
first sequentially applies two parallel discrete lengths 501a of
decorative film tape along the length of the sheet of release liner
508. The tape applicator 10 then cuts those discrete lengths 501a
of decorative film tape to form first and second end portions 204a
and 205a for display lengths 501 of decorative film tape along the
discrete lengths 501a of decorative film tape at the locations that
intersections 220 are to be made by the steps described above with
reference to FIGS. 19 and 20. The opposite ends of the two applied
discrete lengths 501a of decorative film tape are at 90.degree.
angles relative to the lengths of the tape, as cut by the first
cutter 116. Alternatively, those opposite ends could also be cut
obliquely to the lengths of the first applied discrete lengths 501a
of decorative film tape by the second cutter 154 if that were
desired. The tape applicator 10 then returns the head 100 to its
"home position" along the support surface 22, as illustrated in
FIG. 1, to allow a user to remove the scrap portions 98 of the
first discrete lengths 501a of decorative film tape at each
intersection 220 being formed along its length. Next, the tape
applicator 10 moves the tape head 100 to sequentially apply five
parallel discrete lengths 501b of decorative film tape transverse
to the display lengths 502 of decorative film tape formed from the
first two discrete lengths 501a of decorative film tape at a
90.degree. angle to their edges and extending across the end
portions 204a and 205a at the intersections 220. The tape
applicator 10 then sequentially cuts those discrete lengths 501b of
decorative film tape to form first and second end portions 204b and
205b for display lengths 501 of decorative film tape from the
second discrete lengths 501b of decorative film tape at the
intersections 220 using the steps described above. Lastly, the tape
head 100 returns to its "home position" to allow the operator to
remove the scrap portions 99 thus formed at each intersection
220.
As a further example, to form the pattern of display lengths 502 of
decorative film tape illustrated in FIG. 7 the tape applicator 10
first sequentially applies eight parallel discrete lengths 501a of
decorative film tape at an angle along the length of the sheet of
release liner 508. The tape applicator 10 then cuts those discrete
lengths 501a of decorative film tape to form first and second end
portions 204a and 205a for display lengths of decorative film tape
along the discrete lengths 501a of decorative film tape at the
locations that intersections 220 are to be made by the steps
described above with reference to FIGS. 19 and 20. The opposite
ends of each applied discrete length 501a of decorative film tape
is cut obliquely to the length of that applied discrete length 501a
of decorative film tape by the second cutter 154. The tape
applicator 10 then returns the head 100 to its "home position"
along the support surface 22, as illustrated in FIG. 1, to allow a
user to remove the scrap portions 98 of the first discrete lengths
501a of decorative film tape at each intersection 220 being formed
along its length and at the opposite ends of the discrete lengths
501a. Next, the tape applicator 10 moves the tape head 100 to
sequentially apply eight parallel discrete lengths 501b of
decorative film tape transverse to the display lengths 502 of
decorative film tape formed from the first two discrete lengths
501a of decorative film tape at a 90.degree. angle to their edges
and extending across the end portions 204a and 205a at the
intersections 220, which discrete lengths 501b are long enough to
also extend across the opposite ends of the discrete lengths 501a.
The tape applicator 10 then uses the second cutter 154 to
sequentially cut those discrete lengths 501b of decorative film
tape to form first and second end portions 204b and 205b for
display lengths 501 of decorative film tape from the second
discrete lengths 501b of decorative film tape at the intersections
220 using the steps described above, and to cut opposite ends of
each applied discrete length 501a of decorative film tape obliquely
to the length of that applied discrete length 501a of decorative
film tape to form ends for display lengths 501 that are closely
spaced from the ends of display lengths formed from the first
discrete lengths 501a of decorative film tape. Lastly, the tape
head 100 returns to its "home position" to allow the operator to
remove the scrap portions 99 thus formed at each intersection 220
and at each end of the applied discrete length 501a of decorative
film tape.
FIGS. 1 and 7 are only illustrative of patterns of display lengths
of decorative film tape that can be adhered to a sheet of release
liner by the tape applicator 10 in the method according to the
present invention for making a laminate according to the present
invention. The tape applicator 10 may create almost any pattern of
straight display lengths of decorative film tape on a sheet of
release liner because of the versatility with which the tape head
100 can be moved across the support surface 22 to apply discrete
lengths of decorative film tape at any angle along a release liner
on the support surface 22, and (if necessary) to cut the applied
discrete lengths of decorative film tape at any angle after they
have been applied to the release liner to form the display lengths
from those applied discrete lengths.
The tape applicator 10 includes a computer processor and a
controller for sending appropriate signals to the actuators 30, 32,
34 to move the tape head 100 relative to the support surface 22 and
to operate the tape head 100 as necessary to form a desired pattern
of display lengths of the decorative film tape on a sheet of
release liner. For example, an operator may want to make the
pattern of display lengths of decorative film tape on a sheet of
release liner illustrated in either FIG. 1 or FIG. 7. The operator
enters a set of commands into the computer processor that indicate
the shape of the pattern to be made. The computer processor and
controller then determines which way to direct the actuators 30,
32, 34 to move the tape head 100 to apply the discrete lengths of
decorative film tape to the release liner and to cut the applied
discrete lengths of decorative film tape after they have been
applied to the release liner to form the display lengths of
decorative film tape. The computer processor and controller can
include an "open loop" system, which calculates where the tape head
100 is located on the tabletop 21, based on a known series of
moves. For example, the ball screw in either the x-axis actuator 30
or y-axis actuator 32 will move the tape head 100 a known distance
per one rotation of the ball screws. If the computer processor
knows the initial location of the tape head 100, like the "home
position" for instance, it can determine where the final location
of the tape head 100, based on how many rotations the ball screw in
the actuator actually rotated. The computer processor will send a
signal to the x-axis and y-axis actuators 30, 32 to turn the ball
screws a certain number of rotations to move the tape head 100 a
certain distance in a particular axis. The computer processor can
also send signals to the rotary actuator 36 indicating where and
when to rotate the tape head 100 around an axis parallel to the
z-axis of the support surface 22. A suitable controller is a
controller sold under the trade name Compumotor, which is
commercially available from Braas Company located in St. Paul,
Minn., sold under part number 6K4. Alternatively, the computer
processor could include a "closed loop" system, which calculates
where the tape head 100 is at all times on the support surface 22
of the tabletop 21.
The actuators 30, 32, 34 include sensors to determine the initial
location of the tape head 100 on the tabletop 21. Suitable sensors
for the actuators 30, 32, 34 are Prox Sensors sold under the trade
name Omron, which is commercially available from Braas Company
located in St. Paul, Minn., sold under part number
E2E-X1R5E1-M1-N.
The methods and structures according to the present invention have
now been described with reference to several embodiments and
modifications thereof. The foregoing detailed description and
examples have been given for clarity of understanding only. No
unnecessary limitations are to be understood from them. All patents
and patent applications cited herein are hereby incorporated by
reference.
It will be apparent to those skilled in the art that many changes
can be made in the methods and embodiments described without
departing from the scope of the invention. For example, the tape
applicator 10 could be modified and used in an alternative method
for forming essentially the same laminate 500 described above from
the same layer of pre-mask material 510, supply length 92 of
decorative film tape, and release liner 508 described above by
supporting the layer of pre-mask material 510 with the surface of
its layer 512 of removable adhesive opposite its cover layer 5 11
in the application plane, and using the tape applicator 10 to form
display lengths 502 of decorative film tape of different
predetermined lengths and end shapes from the supply length 92 of
decorative film tape and to apply those display lengths 502 of
decorative film tape to the surface of the layer 512 of removable
adhesive in a predetermined pattern in the manner described above
with longitudinal edges of the display lengths 502 of tape
extending along predetermined edge locations, the pattern of
application including aligned closely spaced ends for at least some
of the applied display lengths 502 of decorative film tape, and
then pressing the release liner 508 against the layers 509 of
aggressive adhesive in the display lengths 502 of decorative film
tape and the portions of the layer 512 of removable adhesive
included in the layer of pre-mask material 510 that are exposed
around the display lengths 502 of decorative film tape.
Modifications of the tape applicator 10 so that it could be used in
this method would comprise changing the positions of the fixed
blade 112 and the moveable blade 114 of the first cutter 116, and
positioning the liner take-up roller 136 including its friction
clutch 138 and the motor 137 by which it is driven through the
speed reducer 139 on the opposite side of the tape path, together
with providing an application surface 121 on the roller 120 that
would not adhere to the layer 509 of pressure sensitive adhesive on
the supply length 92 of decorative film tape.
All of the patents and patent applications disclosed herein,
including those set forth in the Background of the Invention, are
hereby incorporated by reference. Although specific embodiments of
this invention have been shown and described herein, it is to be
understood that these embodiments are merely illustrative of the
many possible specific arrangements that can be devised in
application of the principles of the invention. Numerous and varied
other arrangements can be devised in accordance with these
principles by those of ordinary skill in the art without departing
from the scope and spirit of the invention. Thus, the scope of the
present invention should not be limited to the structures described
in this application, but only by the structures described by the
language of the claims and the equivalents of those structures.
* * * * *